Illuminated emblem assemblies and methods of manufacture

ABSTRACT

An illuminated emblem assembly includes a multi-component outer lens having an exterior surface and an interior surface further comprising an externally visible area to be illuminated, an inner lens having an exterior surface and an interior surface, a printed circuit board assembly, a heat sink, a housing for the inner and outer lenses, and at least one light source, wherein the at least one light source is offset from the externally visible area to be illuminated. A method of manufacturing the illuminated emblem assembly includes injection molding the multi-component outer lens, providing the inner lens, providing the housing for the inner and outer lenses, providing the at least one light source, and assembling the inner and outer lenses and the at least one light source within the housing to obtain the illuminated emblem assembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.63/185,964, filed on May 7, 2021, and 63/317,428, filed on Mar. 7, 2022.The disclosures of the above-identified applications are incorporatedherein by reference in their entirety.

FIELD

This disclosure relates to illuminated displays, more specifically toilluminated emblem assemblies and their methods of manufacture.

BACKGROUND

Emblems are used to display branding information or other logos onproducts, such as, but not limited to vehicles. Illumination of anemblem may enhance the visual appearance of an emblem, illuminate theemblem in dark conditions, and/or otherwise draw attention to theemblem. Typical light sources generate light that radiates outwards fromthe light source. However, a radial illumination pattern may not bedesired when the light source is used to illuminate an emblem. Thus,there exists a need for an illuminated emblem assembly with improvedhomogeneity and luminance and a method of manufacturing the same.

The background description provided herein is for the purpose ofgenerally presenting the context of the disclosure. Work of thepresently named inventors, to the extent it is described in thisbackground section, as well as aspects of the description that may nototherwise qualify as prior art at the time of filing, are neitherexpressly nor impliedly admitted as prior art against the presentdisclosure.

SUMMARY

According to one aspect of the present disclosure, an illuminated emblemassembly is presented. In one exemplary implementation, the illuminatedemblem assembly comprises a multi-component outer lens having anexterior surface and an interior surface further comprising anexternally visible area to be illuminated, an inner lens having anexterior surface and an interior surface, a printed circuit boardassembly, a heat sink, a housing for the inner and outer lenses, and atleast one light source, wherein the at least one light source is offsetfrom the externally visible area to be illuminated. According to anotheraspect of the present disclosure, a vehicle body component comprisingthe illuminated emblem assembly and a similar method of manufacture arepresented.

In some implementations, the multi-component outer lens is a multi-shotinjection molded lens. In some implementations, the materials for themulti-shot injection molded lens include at least black polymethylmethacrylate (PMMA) and clear PMMA. In some implementations, the lightsource is a light-emitting diode (LED) assembly having one or more LEDlights. In some implementations, when the externally visible area to beilluminated comprises circular areas, the light source is radiallycentered on each circle offset from the externally visible area to beilluminated. In some implementations, when the externally visible areato be illuminated comprises circular areas, the light source comprisesat least one light source radially offset from a center of each circleoffset from the externally visible area to be illuminated. In someimplementations, the at least one light source radially offset from thecenter of each circle comprises two light sources radially offset fromthe center of each circle in opposing directions. In someimplementations, each circle defines a central elongated or oval-shapedaperture, and wherein the two light sources are radially in directlyopposing directions along a central longer axis line of the respectivecentral aperture

In some implementations, a reflective coating is applied to at least aportion of the interior surface of the outer lens. In someimplementations, at least a portion of the interior surface of the outerlens or the exterior surface of the inner lens is grained or textured.In some implementations, the multicomponent outer lens has at least oneset of alternating solid and open structures, wherein the amount oflight from the light source passing to the area to be illuminated is notmaterially impacted by any alternating structures. In someimplementations, the multi-component outer lens is alternating solid andopen circular areas. In some implementations, the alternating solid andopen circular areas are interlocked. In some implementations, a plane ora surface of entry points of the light source are not stepped orstaggered in relation to the area to be illuminated.

According to another aspect of the present disclosure, a method ofmanufacturing an illuminated emblem assembly is presented. In oneexemplary implementation, the method comprises injection molding amulti-component outer lens having an exterior surface and an interiorsurface further comprising an externally visible area to be illuminated,providing an inner lens having an exterior surface and an interiorsurface, providing a housing for the inner and outer lenses, providingat least one light source, wherein the at least one light source isoffset from the externally visible area to be illuminated, andassembling the inner and outer lenses and the at least one light sourcewithin the housing to obtain the illuminated emblem assembly.

In some implementations, the injection molding of the multi-componentouter lens is a multi-shot injection molding process. In someimplementations, the multi-shot injection molding process comprisesperforming a first injection molding shot to form a first opaque portionof the multi-component outer lens, and performing a second injectionmolding shot before or after the first injection molding shot to form asecond translucent or transparent portion of the multi-component outerlens. In some implementations, the materials for the first and secondinjection molding shots include at least black PMMA and clear PMMA,respectively. In some implementations, the method further comprisesproviding and assembling a printed circuit board assembly and a heatsink within the housing for controlling/powering and heat management ofthe at least one light source.

Further areas of applicability of the teachings of the presentdisclosure will become apparent from the detailed description, claimsand the drawings provided hereinafter, wherein like reference numeralsrefer to like features throughout the several views of the drawings. Itshould be understood that the detailed description, including disclosedembodiments and drawings referenced therein, are merely exemplary innature intended for purposes of illustration only and are not intendedto limit the scope of the present disclosure, its application or uses.Thus, variations that do not depart from the gist of the presentdisclosure are intended to be within the scope of the presentdisclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a sectional side view of a portion of a first exampleilluminated emblem assembly using a lower portion of its inner opticsfor illumination according to some implementations of the presentdisclosure;

FIG. 2 is a sectional side view of a portion of a second exampleilluminated emblem assembly using an upper portion of its inner opticsfor illumination according to some implementations of the presentdisclosure;

FIG. 3 is a sectional side view of a third example illuminated emblemassembly using a both the lower and upper portions of its inner opticsfor illumination according to some implementations of the presentdisclosure;

FIG. 4 is a sectional top view of a portion of a fourth exampleilluminated emblem assembly having illuminated and non-illuminated areascorresponding to solid and open optic rings according to someimplementations of the present disclosure;

FIG. 5 is a sectional top view of a portion of the fifth exampleilluminated emblem assembly having different light source configurationsaccording to some implementations of the present disclosure;

FIGS. 6A-6B are front and cross-sectional (A-A′) views of a portion ofsixth example illuminated emblem assembly according to someimplementations of the present disclosure; and

FIG. 7 is a flow diagram of an example method of manufacturing anilluminated emblem assembly according to some implementations of thepresent disclosure.

While each of the drawing figures illustrates a particular embodimentfor purposes of illustrating a clear example, other embodiments mayomit, add to, reorder, or modify any of the elements shown in thedrawing figures. For purposes of illustrating clear examples, one ormore figures may be described with reference to one or more otherfigures. However, using the particular arrangement illustrated in theone or more other figures is not required in other embodiments.

DETAILED DESCRIPTION

As previously discussed, emblems are used to display brandinginformation or other logos on products, such as, but not limited tovehicles. Illumination of an emblem may enhance the visual appearance ofan emblem, illuminate the emblem in dark conditions, and/or otherwisedraw attention to the emblem. Typical light sources generate light thatradiates outwards from the light source. However, a radial illuminationpattern may not be desired when the light source is used to illuminatean emblem. Thus, there exists a need for an illuminated emblem assemblywith improved homogeneity and luminance and a method of manufacturingthe same. Accordingly, improved illuminated emblem assemblies and theirmethods of manufacture are presented herein. The illuminated emblemassemblies provide for improved homogeneity and luminance, and theirmethods of manufacture provide are simple and efficient. Potentialbenefits include improved viewing aesthetics and/or reducedmanufacturing costs.

Referring now to FIGS. 1-3, sectional side views of various examples ofan illuminated emblem assembly according to some implementations of thepresent disclosure are illustrated. More specifically, FIG. 1 is asectional side view of a portion of a first example illuminated emblemassembly 100 using a lower portion of its inner optics for illuminationand FIG. 2 is a sectional side view of a portion of a second exampleilluminated emblem assembly 200 using an upper portion of its inneroptics for illumination, whereas FIG. 3 is a sectional side view of athird example illuminated emblem assembly 300 using both the lower andupper portions of its inner optics for illumination (i.e., a combinationof portions 100 and 200, referenced as 100 a, 100 b, 200 a, and 200 b).The illuminated emblem assemblies generally comprise a multi-componentouter lens 104 having an exterior surface 104 a and an interior surface104 b further comprising an externally visible area 140 to beilluminated, an inner lens 112 having an exterior surface 112 a and aninterior surface 112 b, a printed circuit board (PCB) assembly 132, aheat sink (HS) 136, a housing 124 for the inner and outer lenses 112,104, and at least one light source 128, wherein the at least one lightsource is offset from the externally visible area 140 to be illuminated.In some implementations, the multi-component outer lens is a multi-shot(e.g., two-shot, or 2K) injection molded lens formed of two differentmaterials 108 a, 108 b. In some implementations, the materials for themulti-shot injection molded lens include at least black (e.g., opaque)polymethyl methacrylate (PMMA) and clear (e.g., transparent ortranslucent) PMMA for materials 108 a, 108 b, respectively.

Referring now to FIGS. 4-5 and with continued reference to FIGS. 1-3,sectional top views of a portion of a fourth example illuminated emblemassembly 400 having illuminated and non-illuminated areas correspondingto solid and open optic rings and a portion of the fifth exampleilluminated emblem assembly 500 having different light sourceconfigurations according to some implementations of the presentdisclosure are illustrated. In one exemplary implementation, the lightsource 128 is a light-emitting diode (LED) assembly having one or moreLED lights that is controlled by the PCB assembly 132 and having heatmanagement regulated via the heat sink (HS) 136. A reflective coatingmay be applied to at least a portion of the interior surface 104 b ofthe outer lens 104, such as in portions where light is not to betransmissive therethrough as shown. In some implementations, at least aportion of the interior surface 104 b of the outer lens and/or theexterior surface 112 a of the inner lens 112 is grained or textured (see120). This graining or texturing of these surface(s) can create lightingeffects, such as by alternating the diffusiveness of the light passingtherethrough.

Referring now to FIGS. 6A-6B and with continued reference to theprevious FIGS., front and cross-sectional (A-A′) views of a portion ofsixth example illuminated emblem assembly 600 according to someimplementations of the present disclosure are illustrated. when theexternally visible area to be illuminated comprises circular areas 604,the light source comprises at least one light source 616 a and/or 616 bradially offset from a center of each circle 604 offset from theexternally visible area to be illuminated (i.e., via a central aperture608) while still achieving the requisite lighting quality demands. Thisexternally visible area to be illuminated could also include non-centralapertures 612 a and/or 612 b as shown. In such implementations, the atleast one light source radially offset from the center of each circle604 comprises two light sources 616 a, 616 b radially offset from thecenter of each circle in opposing directions. In some implementations,the two light sources 616 a, 616 b are radially offset in directlyopposing directions in line with and parallel to an elongated length(e.g., along a central axis line of the circumference) relative to acentral elongated or oval-shaped aperture 608 as shown in FIG. 6A.

These light sources 616 a, 616 b could be affixed/attached to orintegrated into a back or rear surface of the illuminated emblemassembly 600. Each light source 616 a, 616 b, for example, could be anLED recessed in a back surface of the illuminated emblem assembly 600 inrespective recessed areas 620 a, 620 b as shown such that the overallprofile of the illuminated emblem assembly 600 remains flat orlow-profile. In some implementations, the multicomponent outer lens 104has at least one set of alternating solid and open structures, whereinthe amount of light from the light source passing to the area 140 to beilluminated is not materially impacted by any alternating structures(e.g., especially if the alternating structures are superimposed). Insome implementations, the multi-component outer lens is alternatingsolid and open circular areas (see FIG. 4). In some implementations, thealternating solid and open circular areas are interlocked (see FIG. 6).In some implementations, a plane or a surface of entry points of thelight source are not stepped or staggered in relation to the area to beilluminated.

In some implementations, the illuminated emblem assembly is part of anautomotive or vehicle body component (e.g., attached to or integratedtherein). Non-limiting examples of such vehicle body components includegrille assemblies, bumpers, side moldings, and rear elements (hatches,trunk lid finishers, etc.). While exterior vehicle body components arespecifically discussed, it will be appreciated that these systems andmethods (see below) could be applicable to other automotive components,such as interior vehicle components.

Referring now to FIG. 7, a flow diagram of an example method 700 ofmanufacturing an illuminated emblem assembly (e.g., assembly100/200/300) according to some embodiments of the present application isillustrated. At 704, injection molding of a multi-component outer lenshaving an exterior surface and an interior surface further comprising anexternally visible area to be illuminated is performed. This couldinclude, for example, a multi-shot injection molding process, such asperforming a first injection molding shot at 704 a to form a firstopaque portion of the multi-component outer lens and performing a secondinjection molding shot 704 b before or after the first injection moldingshot 704 a to form a second translucent or transparent portion of themulti-component outer lens. As previously discussed, the materials forthe first and second injection molding shots include at least black PMMAand clear PMMA, respectively, but it will be appreciated that othersuitable materials could be utilized.

While not shown as a separate step, it will be appreciated that themulti-component outer lens could be removed from a mold after theinjection molding process. At 708, an inner lens having an exteriorsurface and an interior surface is provided. At 712, a housing for theinner and outer lenses is provided. At 716, at least one light sourceoffset from the externally visible area to be illuminated is provided.Lastly, at 724, the inner and outer lenses and the at least one lightsource are assembly within the housing to obtain the illuminated emblemassembly (e.g., assembly 100 and/or 200). At optional intermediary step720, a PCB assembly and a heat sink could be provided and also assembledwithin the housing for controlling/powering and heat management of theat least one light source. The method 700 then ends or returns to 704for one or more additional manufacturing cycles.

Example embodiments are provided so that this disclosure will bethorough, and will fully convey the scope to those who are skilled inthe art. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known procedures,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an,” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The term “and/or” includes any and all combinations of one ormore of the associated listed items. The terms “comprises,”“comprising,” “including,” and “having,” are inclusive and thereforespecify the presence of stated features, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,elements, components, and/or groups thereof. The method steps,processes, and operations described herein are not to be construed asnecessarily requiring their performance in the particular orderdiscussed or illustrated, unless specifically identified as an order ofperformance. It is also to be understood that additional or alternativesteps may be employed.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,layer or section discussed below could be termed a second element,component, region, layer or section without departing from the teachingsof the example embodiments.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements or featuresof a particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the disclosure, and all such modificationsare intended to be included within the scope of the disclosure.

What is claimed is:
 1. An illuminated emblem assembly comprising: amulti-component outer lens having an exterior surface and an interiorsurface further comprising an externally visible area to be illuminated;an inner lens having an exterior surface and an interior surface; aprinted circuit board assembly; a heat sink; a housing for the inner andouter lenses; and at least one light source, wherein the at least onelight source is offset from the externally visible area to beilluminated.
 2. The illuminated emblem assembly of claim 1, wherein themulti-component outer lens is a multi-shot injection molded lens.
 3. Theilluminated emblem assembly of claim 2, wherein the materials for themulti-shot injection molded lens include at least black polymethylmethacrylate (PMMA) and clear PMMA.
 4. The illuminated emblem assemblyof claim 1, wherein the light source is a light-emitting diode (LED)assembly having one or more LED lights.
 5. The illuminated emblemassembly of claim 1, wherein when the externally visible area to beilluminated comprises circular areas, the light source is radiallycentered on each circle offset from the externally visible area to beilluminated.
 6. The illuminated emblem assembly of claim 1, wherein whenthe externally visible area to be illuminated comprises circular areas,the light source comprises at least one light source radially offsetfrom a center of each circle offset from the externally visible area tobe illuminated.
 7. The illuminated emblem assembly of claim 6, whereinthe at least one light source radially offset from the center of eachcircle comprises two light sources radially offset from the center ofeach circle in opposing directions.
 8. The illuminated emblem assemblyof claim 7, wherein each circle defines a central elongated oroval-shaped aperture, and wherein the two light sources are radially indirectly opposing directions along a central longer axis line of therespective central aperture
 9. The illuminated emblem assembly of claim1, wherein a reflective coating is applied to at least a portion of theinterior surface of the outer lens.
 10. The illuminated emblem assemblyof claim 1, wherein at least a portion of the interior surface of theouter lens or the exterior surface of the inner lens is grained ortextured.
 11. The illuminated emblem assembly of claim 1, wherein themulticomponent outer lens has at least one set of alternating solid andopen structures, wherein the amount of light from the light sourcepassing to the area to be illuminated is not materially impacted by anyalternating structures.
 12. The illuminated emblem assembly of claim 11,wherein the multi-component outer lens is alternating solid and opencircular areas.
 13. The illuminated emblem assembly of claim 12, whereinthe alternating solid and open circular areas are interlocked.
 14. Theilluminated emblem assembly of claim 1, wherein a plane or a surface ofentry points of the light source are not stepped or staggered inrelation to the area to be illuminated.
 15. A vehicle body componentcomprising the illuminated emblem assembly of claim
 1. 16. A method ofmanufacturing an illuminated emblem assembly, the method comprising:injection molding a multi-component outer lens having an exteriorsurface and an interior surface further comprising an externally visiblearea to be illuminated; providing an inner lens having an exteriorsurface and an interior surface; providing a housing for the inner andouter lenses; providing at least one light source, wherein the at leastone light source is offset from the externally visible area to beilluminated; and assembling the inner and outer lenses and the at leastone light source within the housing to obtain the illuminated emblemassembly.
 17. The method of claim 16, wherein the injection molding ofthe multi-component outer lens is a multi-shot injection moldingprocess.
 18. The method of claim 17, wherein the multi-shot injectionmolding process comprises: performing a first injection molding shot toform a first opaque portion of the multi-component outer lens; andperforming a second injection molding shot before or after the firstinjection molding shot to form a second translucent or transparentportion of the multi-component outer lens.
 19. The method of claim 18,wherein the materials for the first and second injection molding shotsinclude at least black polymethyl methacrylate (PMMA) and clear PMMA,respectively.
 20. The method of claim 16, further comprising providingand assembling a printed circuit board assembly and a heat sink withinthe housing for controlling/powering and heat management of the at leastone light source.